HMV Highly Maneuverable Vehicle Zoom 300 and Zoom 400

Transcription

1 Service Manual HMV Highly Maneuverable Vehicle Zoom 300 and Zoom 400 DEALER: Keep this manual. The procedures in this manual must be performed by a qualified technician. For more information regarding Invacare products, parts, and services, please visit

2 WARNING THE PROCEDURES IN THIS SERVICE MANUAL MUST BE PERFORMED BY A QUALIFIED TECHNICIAN. DO NOT SERVICE OR OPERATE THIS EQUIPMENT WITHOUT FIRST READING AND UNDERSTANDING (1) THE OWNER S OPERATOR AND MAINTENANCE MANUAL AND (2) THE SERVICE MANUAL. IF YOU ARE UNABLE TO UNDERSTAND THE WARNINGS, CAUTIONS AND INSTRUCTIONS, CONTACT INVACARE TECHNICAL SUPPORT BEFORE ATTEMPTING TO SERVICE OR OPERATE THIS EQUIPMENT - OTHERWISE, INJURY OR DAMAGE MAY RESULT. NOTE: Updated versions of this manual are available on Zoom 300 and Zoom Part No

3 TABLE OF CONTENTS TABLE OF CONTENTS SPECIAL NOTES... 8 TYPICAL PRODUCT PARAMETERS... 9 LABEL LOCATIONS On Zoom On Zoom SECTION 1 GENERAL GUIDELINES Repair or Service Information...12 Operation Information...12 Tire Pressure...13 Electrical...13 Grounding Instructions...13 Batteries...13 Charging Batteries...14 Rain Test...14 Weight Limitation...14 SECTION 2 EMI INFORMATION SECTION 3 SAFETY INSPECTION Checklist...17 SECTION 4 SEAT Removing/Installing the Seat...19 Removing...19 Installing...19 Removing/Installing the Seat Post...20 Removing...20 Installing...20 Adjusting Seat Height...21 Removing/Installing the Seat Pivot...21 Removing...21 Installing...21 Adjusting Seat Depth Seat Swivel Adjustment...23 Removing/Installing the Seat Positioning Strap...24 SECTION 5 ARMS Part No Zoom 300 and Zoom 400

4 TABLE OF CONTENTS TABLE OF CONTENTS Removing/Installing/Adjusting Arms...25 Removing/Installing...25 Adjusting Arm Width...26 Adjusting Arm Angle...26 Adjusting Arm Height...27 Replacing Armrest Pads...28 Removing/Installing Arm Support Bracket...28 SECTION 6 SHROUDS Removing/Installing the Rear Shroud...30 Removing...30 Installing...30 Removing/Installing the Front Shroud...31 Zoom Zoom Removing/Installing the Boot Assembly...33 SECTION 7 WHEELS AND CASTERS Removing/Installing the Drive Wheels...34 Removing...34 Installing...34 Removing/Installing the Front Wheel...36 Removing...36 Installing...36 Removing/Installing the Fork...37 Removing...37 Installing...37 Removing/Installing the Caster Assemblies...38 Removing...38 Installing...38 Replacing Foam-Filled Tires Onto Wheel Rims...39 SECTION 8 TILLER Removing/Installing the Tiller...40 Zoom Zoom Adjusting the Tiller Angle...43 Replacing Handgrips...43 Zoom 300 and Zoom Part No

5 TABLE OF CONTENTS TABLE OF CONTENTS Removing/Installing the Upper Tiller Shroud...44 Removing...44 Installing...44 Removing/Installing the Rear Tiller Shroud...46 Removing...46 Installing...46 Removing/Installing the Headlight...47 Removing...47 Installing...47 Removing/Installing the Headlight Mounting Bracket/Front Tiller Shroud...48 Removing...48 Installing...48 Replacing the Ignition Switch...49 Replacing the Horn...50 Replacing the Headlight Switch...51 Replacing the PC Board...52 Removing/Installing the Tiller Angle Adjustment Assembly...54 Removing...54 Installing...54 Replacing the Tiller Wiring Harness...55 Changing to Left-Handed Operation...58 Replacing the Throttle Assembly...58 Calibrating Throttle Potentiometer...59 Mechanical Method...59 Programming Method...61 SECTION 9 SWINGARMS Removing/Installing the Swingarms...62 Removing...62 Installing...62 SECTION 10 TRANSAXLE Removing/Installing the Transaxle...64 Removing...64 Installing...64 Removing/Installing the Brake Release Lever...65 Removing...65 Installing...65 Part No Zoom 300 and Zoom 400

6 TABLE OF CONTENTS TABLE OF CONTENTS Disengaging/Engaging the Brake Release Lever...66 SECTION 11 CONTROLLER Removing/Installing the Controller...68 Removing...68 Installing...69 Replacing the Controller Tray...70 Zoom Zoom Removing/Installing Rear Wiring Harness...74 Replacing/Resetting the Circuit Breaker...76 Replacing...76 Resetting Circuit Breaker...78 Replacing the Fuse...79 Changing to Left-Handed Operation...80 Programming the Controller...80 Plugging in the Programmer...80 Main Menu...81 Set Up Menu...81 Options Menu...82 Speed Lever in Neutral Menu...83 Controller Version Menu...83 SECTION 12 BATTERIES AND CHARGER Recommended Battery Type...85 Removing/Installing the Batteries on Zoom Removing...86 Installing...86 Removing/Installing the Batteries on Zoom Removing...88 Installing...88 Connecting/Disconnecting the Battery Cables on the Zoom Connecting...90 Disconnecting...91 Replacing the Charger...92 Zoom Zoom Zoom 300 and Zoom Part No

7 Charging the Batteries...97 On-Board Battery Charger...97 Battery Charger Operation - Charger Indicator Light on Tiller...98 SECTION 13 MAINTENANCE AND TROUBLESHOOTING Storing the Scooter...99 Suggested Maintenance Procedures...99 Lubrication Points Electrical Controller Error Codes SECTION 14 TRANSPORTING Disassembling/Assembling the Zoom Disassembling Assembling Disassembling/Assembling the Zoom Disassembling Assembling SECTION 15 SCOOTER ACCESSORIES Removing/Installing the Front Basket Removing/Installing the Front Basket Mounting Bracket Removing Installing Installing/Removing the Crutch/Cane Holder Installing Removing Installing/Removing the Safety Flag Installing Removing Installing/Removing/Using the Walker Holder Installing/Removing the Walker Holder Using the Walker Holder Installing/Removing the Rear Mounted Basket Installing Removing LIMITED WARRANTY Part No Zoom 300 and Zoom 400

8 SPECIAL NOTES SPECIAL NOTES Signal words are used in this manual and apply to hazards or unsafe practices which could result in personal injury or property damage. Refer to the table below for definitions of the signal words. SIGNAL WORD DANGER WARNING CAUTION MEANING Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Caution indicates a potentially hazardous situation which, if not avoided, may result in property damage. NOTICE THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE. As a manufacturer of powered scooters, Invacare endeavors to supply a wide variety of powered scooters to meet many needs of the end user. However, final selection of the type of powered scooter to be used by an individual rests solely with the user and his/her healthcare professional capable of making such a selection. TIE-DOWN RESTRAINTS AND SEAT RESTRAINTS Powered scooter users should NOT be transported in vehicles of any kind while in the powered scooter. As of this date, the Department of Transportation has not approved any tie-down systems for transportation of a user while in a powered scooter, in a moving vehicle of any type. It is Invacare s position that users of powered scooters should be transferred into appropriate seating in vehicles for transportation and use be made of the restraints made available by the auto industry. Invacare cannot and does not recommend any powered scooter transportation systems. SEAT POSITIONING STRAP It is the obligation of the dealers, therapists and other healthcare professionals to determine if a seating restraint is required to ensure the safe operation of this equipment by the user. Serious injury can occur in the event of a fall from a powered scooter. WARNING The seat positioning strap is a positioning belt ONLY. It is not designed for use as a safety device withstanding high stress loads such as auto or aircraft safety belts. If signs of wear appear, belt must be replaced immediately. Invacare products are specifically designed and manufactured for use in conjunction with Invacare accessories. Accessories designed by other manufacturers have not been tested by Invacare and are not recommended for use with Invacare products. Part No Zoom 300 and Zoom 400

9 TYPICAL PRODUCT PARAMETERS TYPICAL PRODUCT PARAMETERS OVERALL DIMENSIONS* BASE LENGTH: BASE WIDTH: STEP HEIGHT (Floor Pan to Ground): SEAT HEIGHT (Floor Pan to Seat Cushion): SEAT DIMENSIONS WIDTH: DEPTH: BACK HEIGHT: ARM DIMENSIONS LENGTH: HEIGHT BETWEEN SEAT AND ARMS: WIDTH BETWEEN ARMS: SPEED RANGE: 44 in in. 3.5 in in. ZOOM 300 ZOOM in. 18 in. 16, 17, 18 in. 16, 17, 18 in. 15 in. 17 in. 13 in. 7-9 in. 16 in. seat in. 18 in. seat in m.p.h. (Factory setting m.p.h.) 46 in. 24 in. 4.5 in in. MAXIMUM WEIGHT LIMITATION: 300 lbs 400 lbs MAXIMUM INCLINE CAPABILITY: 8 Grade 8 Grade WHEELS FRONT WHEEL: DRIVE WHEEL: REAR CASTER: 7 in. x 2 in. 8 in. x 3 in. 1 in. x 5 in. TURNING RADIUS: 29 in. 32 in. WEIGHT OF PRODUCT FRONT BASE SECTION (WITH BASKET): REAR BASE SECTION (WITH SHROUDS): ENTIRE BASE SECTION: SEAT (WITH ARMS): BATTERIES (QUANTITY - 2): N/A N/A 71 lbs 31 lbs 18 lbs 18 in. 20 in. 16, 17, 18 in. 18, 19, 20 in. 17 in. 19 in. 13 in. 7-9 in. 18 in. seat in. 20 in. seat in m.p.h. (Factory setting m.p.h.) 8 in. x 2 in. 10 in. x 3 in. 1 in. x 5 in. 53 lbs 48 lbs 38 lbs 46 lbs TOTAL WEIGHT OF PRODUCT (Including Batteries): 120 lbs 185 lbs *NOTE: Zoom 300 parameters are based on an 18-inch wide seat. Zoom 400 parameters are based on a 20-inch wide seat. Part No Zoom 300 and Zoom 400

10 LABEL LOCATIONS On Zoom 300 LABEL LOCATIONS NOTE: Serial Number is located under the rear shroud. NOTE: Warning Label is located under the rear shroud.! WARNING Scooter Frame Pinch Point NOTE: Warning Label is also located on the other swingarm. Part No Zoom 300 and Zoom 400

11 LABEL LOCATIONS On Zoom 400 NOTE: Serial Number is located under the rear shroud. DO NOT operate the scooter unless the tiller is in the locked position. NOTE: Warning Label is located under the rear shroud. DO NOT lean against or pull forward on the tiller while mounting or dismounting the scooter. Otherwise, injury may occur DO NOT lift scooter up by the front or rear shroud. Otherwise injury or damage to the scooter may occur Rev A Rear Frame Assembly! WARNING Pinch Point Front Frame Assembly! WARNING Pinch Point Part No Zoom 300 and Zoom 400

12 SECTION 1 GENERAL GUIDELINES SECTION 1 GENERAL GUIDELINES WARNING SECTION 1 - GENERAL GUIDELINES contains important information for the safe operation and use of this product. DO NOT use or service this product or any available optional equipment without first completely reading and understanding these instructions and any additional instructional material such as Owner s Manuals, Service Manuals or Instruction Sheets supplied with this product or optional equipment. If you are unable to understand the Warnings, Cautions or Instructions, contact a healthcare professional, dealer or technical personnel before attempting to use or service this equipment - otherwise, injury or damage may occur. Repair or Service Information Set-up of the electronic control unit is to be performed only by qualified technicians. The final adjustments of the controller may affect other activities of the powered scooter. Damage to the equipment could occur under these circumstances. DO NOT service or adjust your powered scooter while occupied, unless otherwise noted. Operation Information Invacare products are specifically designed and manufactured for use in conjunction with Invacare accessories. Accessories designed by other manufacturers have not been tested by Invacare and are not recommended for use with Invacare products. Performance adjustments should only be made by professionals of the healthcare field or persons fully conversant with this process and the driver's capabilities. Incorrect settings could cause injury to the driver, bystanders, damage to the scooter and to surrounding property. After the powered scooter has been set-up/adjusted, check to make sure that the powered scooter performs to the specifications entered during the set-up procedure. If the powered scooter does not perform to specifications, turn the powered scooter off immediately and reenter set-up specifications. Repeat this section until the powered scooter performs to specifications. Before using the scooter, verify that the motor is plugged into the harness. DO NOT connect any medical devices such as ventilators, life support machines, etc., to the battery. This could cause unexpected failure of the device and the powered scooter. DO NOT attempt to lift the powered scooter by any removable (detachable) parts. Lifting by means of any removable (detachable) parts of a powered scooter may result in injury to the user or damage to the powered scooter. DO NOT attempt to lift the powered scooter by its tiller, seat or shrouds. Zoom 300 and Zoom Part No

13 SECTION 1 GENERAL GUIDELINES DO NOT stand on the frame of the powered scooter. DO NOT stand on the shroud(s) of the powered scooter. DO NOT adjust the seat position outside the specifications recommended by the manufacturer. After making any tiller angle adjustment and before use, the tiller must be securely locked into position. Otherwise the user may fall from the scooter resulting in bodily harm and/ or damage to the scooter. Gently push/pull the tiller to ensure that the tiller is securely engaged. On Zoom 400 only - Before use, ensure that the frame lock lever is in the locked position securing the front and rear frame assemblies together. Otherwise injury and/or damage may occur. DO NOT use an escalator to move a powered scooter between floors. Serious bodily injury may occur. DO NOT overtighten hardware attaching to the frame. This could cause damage to the frame tubing. Avoid storage or use near external flame or combustible products. Tire Pressure Ensure that the powered scooter has the proper tire pressure (P.S.I.). DO NOT overinflate the tires. Failure to follow these recommendations may cause the tire to explode and cause bodily harm. The recommended tire pressure is listed on the side wall of the tire. Electrical Grounding Instructions DO NOT, under any circumstances, cut or remove the round grounding prong from any plug used with or for Invacare products. Some devices are equipped with three-prong (grounding) plugs for protection against possible shock hazards. Where a two-prong wall receptacle is encountered, it is the personal responsibility and obligation of the customer to contact a qualified electrician and have the two-prong receptacle replaced with a properly grounded three-prong wall receptacle in accordance with the National Electrical Code. If you must use an extension cord, use only a three-wire extension cord having the same or higher electrical rating as the device being connected. In addition, Invacare has placed RED/ORANGE warning tags on some equipment. DO NOT remove these tags. Batteries The warranty and performance specifications contained in this manual are based on the use of deep cycle gel cell batteries. Invacare strongly recommends their use as the power source for this unit. Part No Zoom 300 and Zoom 400

14 SECTION 1 GENERAL GUIDELINES Carefully read battery/battery charger information prior to installing or servicing the powered scooter. Charging Batteries NEVER attempt to recharge the batteries by attaching cables directly to the battery terminals. DO NOT attempt to recharge the batteries and operate the wheelchair at the same time. DO NOT operate wheelchair with extension cord attached to the AC cable. DO NOT attempt to recharge the batteries when the wheelchair has been exposed to any type of moisture. DO NOT attempt to recharge the batteries when the wheelchair is outside. DO NOT sit in the wheelchair while charging the batteries. Read and carefully follow the manufacturer s instructions for each charger (supplied or purchased). If charging instructions are not supplied, consult a qualified technician for proper procedures. When using an extension cord, use only a three (3) wire extension cord having at least 16 AWG (American Wire Gauge) wire and the same or higher electrical rating as the device being connected. Use of improper extension cord could result in risk of fire and electric shock. Ensure the pins of the extension cord plug are the same number, size, and shape as those on the charger. DO NOT under any circumstances cut or remove the round grounding plug from the charger AC cable plug or the extension cord plug. Three (3) prong to two (2) prong adapters should not be used. Use of three (3) prong adapters can result in improper grounding and present a shock hazard to the user. Rain Test Invacare has tested its powered scooters in accordance with ISO 7176 Rain Test. Passing this test means that the end user or his/her attendant should have sufficient time to remove his/her powered scooter from a rain storm and retain powered scooter operation. DO NOT leave powered scooter in a rain storm of any kind. DO NOT leave powered scooter in a damp area for any length of time. Weight Limitation The weight limitation for the Zoom 300 is 300 lbs. The weight limitation for the Zoom 400 is 400 lbs. If so equipped, the front basket is rated for a maximum loading capacity of 10 lbs. Zoom 300 and Zoom Part No

15 SECTION 2 EMI INFORMATION SECTION 2 EMI INFORMATION WARNING CAUTION: IT IS VERY IMPORTANT THAT YOU READ THIS INFORMATION REGARDING THE POSSIBLE EFFECTS OF ELECTROMAGNETIC INTERFERENCE ON YOUR POWERED WHEELCHAIR. Electromagnetic Interference (EMI) From Radio Wave Sources Powered wheelchairs and motorized scooters (in this text, both will be referred to as powered wheelchairs) may be susceptible to electromagnetic interference (EMI), which is interfering electromagnetic energy (EM) emitted from sources such as radio stations, TV stations, amateur radio (HAM) transmitters, two way radios, and cellular phones. The interference (from radio wave sources) can cause the powered wheelchair to release its brakes, move by itself, or move in unintended directions. It can also permanently damage the powered wheelchair's control system. The intensity of the interfering EM energy can be measured in volts per meter (V/m). Each powered wheelchair can resist EMI up to a certain intensity. This is called its "immunity level." The higher the immunity level, the greater the protection. At this time, current technology is capable of achieving at least a 20 V/m immunity level, which would provide useful protection from the more common sources of radiated EMI. There are a number of sources of relatively intense electromagnetic fields in the everyday environment. Some of these sources are obvious and easy to avoid. Others are not apparent and exposure is unavoidable. However, we believe that by following the warnings listed below, your risk to EMI will be minimized. The sources of radiated EMI can be broadly classified into three types: 1) Hand-held Portable transceivers (transmitters-receivers with the antenna mounted directly on the transmitting unit. Examples include: citizens band (CB) radios, "walkie talkie", security, fire and police transceivers, cellular telephones, and other personal communication devices). NOTE: Some cellular telephones and similar devices transmit signals while they are ON, even when not being used. 2) Medium-range mobile transceivers, such as those used in police cars, fire trucks, ambulances and taxis. These usually have the antenna mounted on the outside of the vehicle; and 3) Long-range transmitters and transceivers, such as commercial broadcast transmitters (radio and TV broadcast antenna towers) and amateur (HAM) radios. NOTE: Other types of hand-held devices, such as cordless phones, laptop computers, AM/FM radios, TV sets, CD players, cassette players, and small appliances, such as electric shavers and hair dryers, so far as we know, are not likely to cause EMI problems to your powered wheelchair. Part No Zoom 300 and Zoom 400

16 SECTION 2 EMI INFORMATION WARNING Powered Wheelchair Electromagnetic Interference (EMI) Because EM energy rapidly becomes more intense as one moves closer to the transmitting antenna (source), the EM fields from hand-held radio wave sources (transceivers) are of special concern. It is possible to unintentionally bring high levels of EM energy very close to the powered wheelchair's control system while using these devices. This can affect powered wheelchair movement and braking. Therefore, the warnings listed below are recommended to prevent possible interference with the control system of the powered wheelchair. Electromagnetic interference (EMI) from sources such as radio and TV stations, amateur radio (HAM) transmitters, two-way radios, and cellular phones can affect powered wheelchairs and motorized scooters. FOLLOWING THE WARNINGS LISTED BELOW SHOULD REDUCE THE CHANCE OF UNINTENDED BRAKE RELEASE OR POWERED WHEELCHAIR MOVEMENT WHICH COULD RESULT IN SERIOUS INJURY. 1) Do not operate hand-held transceivers (transmitters receivers), such as citizens band (CB) radios, or turn ON personal communication devices, such as cellular phones, while the powered wheelchair is turned ON; 2) Be aware of nearby transmitters, such as radio or TV stations, and try to avoid coming close to them; 3) If unintended movement or brake release occurs, turn the powered wheelchair OFF as soon as it is safe; 4) Be aware that adding accessories or components, or modifying the powered wheelchair, may make it more susceptible to EMI (NOTE: There is no easy way to evaluate their effect on the overall immunity of the powered wheelchair); and 5) Report all incidents of unintended movement or brake release to the powered wheelchair manufacturer, and note whether there is a source of EMI nearby. Important Information 1) 20 volts per meter (V/m) is a generally achievable and useful immunity level against EMI (as of May 1994) (the higher the level, the greater the protection); 2) This device has been tested to a radiated immunity level of 20 volts per meter. Modification of any kind to the electronics of this wheelchair as manufactured by Invacare may adversely affect the RFI immunity levels. Zoom 300 and Zoom Part No

17 SECTION 3 SAFETY INSPECTION SECTION 3 SAFETY INSPECTION Checklist These adjustments should be made whenever you service this product, especially as a part of the initial set up. Follow these maintenance procedures: WARNING Before performing any maintenance, adjustment or service, turn power OFF and remove key from ignition. CAUTION As with any vehicle, the wheels and tires should be checked periodically for cracks and wear, and should be replaced. Ensure powered scooter drives straight (no excessive drag or pull to one side). Check frame for damage and corrosion. Ensure that the brake release lever is easy to engage/disengage. Ensure that tiller adjustment handle engages and disengages properly and securely. Ensure that the scooter stops completely when throttle is released (i.e., does not continue to roll as if the throttle is activated). Clean upholstery and armrests. Ensure adjustable height arms operate and lock securely. Ensure armrest pad sits flush against arm tube. Inspect the seat upholstery for rips and tears. Inspect seat swivel for release and engagement (seat locks into the determined swivel positions). Inspect the seat positioning strap for signs of wear. Replace if worn or damaged. Ensure that the buckle on the seat positioning strap latches. Replace if necessary. Verify that the hardware that attaches the seat positioning strap to the seat frame is secure and undamaged. Replace if necessary. Ensure that the seat mounting hardware is securely tightened. Inspect for excessive side movement or binding when the drive wheels are raised and/ or turned. Inspect front wheel/fork assembly for proper tension by spinning the wheel. The front wheel should come to a gradual stop. Check brake for binding or interference with travel. Check the front fork for damage or corrosion. Part No Zoom 300 and Zoom 400

18 SECTION 3 SAFETY INSPECTION Tighten locknut if the front wheel wobbles noticeably or loosen locknut if the wheel binds to a stop. Ensure that the fork stem bearing set is tight. Ensure that wheel bearings are clean and free of moisture. Ensure that the bolts and fasteners on the caster assemblies are tight. Inspect caster assembly for proper tension by spinning the caster. The caster should come to a gradual stop. Inspect tires for flat spots and wear. Clean molded body shrouds. Lubricate the top of the seat post using a Teflon lubricant. Ensure that the anti-roll safety feature is working properly. The scooter should not free-wheel downhill. Zoom 300 and Zoom Part No

19 SECTION 4 SEAT SECTION 4 SEAT WARNING After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may result. Before performing any maintenance, adjustment or service, turn power OFF and remove key from ignition. Removing/Installing the Seat NOTE: For this procedure, refer to FIGURE 4.1. Removing 1. Fold down seat back. 2. Pulling up on the seat lever, lift the seat assembly off the seat post. Installing 1. Align the seat pivot with the seat post. 2. Pulling up on the seat lever, lower the seat assembly onto the seat post. NOTE: If necessary, slightly twist seat assembly back and forth to lock in place. 3. Release seat lever and lift up on seat assembly to ensure the seat is secure. Seat Back Seat Seat Lever Seat Pivot (Located under the Seat) Seat Post FIGURE 4.1 Removing/Installing the Seat Part No Zoom 300 and Zoom 400

20 SECTION 4 SEAT Removing/Installing the Seat Post WARNING Ensure that the seat post mounting screw is properly engaged and locked. Otherwise, injury and/or damage may result. NOTE: For this procedure, refer to FIGURE 4.2. NOTE: Take note of position and orientation of the seat post and seat post mounting screw before removing. Removing 1. Remove the seat. Refer to Removing/Installing the Seat on page Remove the mounting screw, locknut, and two (2) washers securing the seat post to the frame post, refer to FIGURE Lift seat post up and remove from frame post. Installing 1. Insert the seat post into the frame post and align the frame post mounting hole with the desired seat post mounting hole, refer to FIGURE Using the mounting screw, locknut, and two (2) washers, secure the seat post to the frame post. 3. Install the seat. Refer to Removing/Installing the Seat on page 19. Seat Post Seat Post Mounting Holes Washer Locknut Mounting Screw Frame Post Mounting Hole Washer Frame Post NOTE: Seat post on Zoom 300 shown. Seat post on Zoom 400 installs the same way. FIGURE 4.2 Removing/Installing the Seat Post Zoom 300 and Zoom Part No

21 SECTION 4 SEAT Adjusting Seat Height NOTE: For this procedure, refer to FIGURE 4.3. NOTE: The seat post has three (3) height settings. 1. Remove the seat. Refer to Removing/Installing the Seat on page Remove the mounting screw, locknut, and two (2) washers securing the seat post to the frame post. 3. Align one (1) of the three (3) seat post mounting holes with the frame post mounting hole to achieve desired seat height (FIGURE 4.3). 4. Using the mounting screw, locknut, and two (2) washers, secure the seat post to the frame post. 5. Install the seat. Refer to Removing/ Installing the Seat on page Mounting Hole 18 Mounting Hole 19 Mounting Hole Seat Post FIGURE 4.3 Adjusting Seat Height Removing/Installing the Seat Pivot NOTE: For this procedure, refer to FIGURE 4.4. Removing 1. Remove the seat. Refer to Removing/ Installing the Seat on page Remove the four (4) mounting bolts and washers that secure the seat pivot to the seat. Installing 1. Install the four (4) mounting bolts and washers to secure the seat pivot to the seat. Securely tighten. 2. Install the seat. Refer to Removing/ Installing the Seat on page 19. Seat Pivot Washers Mounting Bolts Seat Washers Mounting Bolts FIGURE 4.4 Removing/Installing the Seat Pivot Part No Zoom 300 and Zoom 400

22 SECTION 4 SEAT Adjusting Seat Depth WARNING DO NOT adjust the seat position outside the specifications recommended by the manufacturer. Otherwise, injury to user or damage to scooter may result. NOTE: For this procedure, refer to FIGURE Remove the seat assembly from the scooter. Refer to Removing/Installing the Seat on page Remove the adjustable width arms. Refer to Removing/Installing/Adjusting Arms on page Remove the six (6) mounting screws located under the seat that secure the back assembly to the seat base. 4. Adjust back assembly to one (1) of three (3) mounting positions. 5. Reinstall the six (6) mounting screws securing the back assembly to the seat base. Securely tighten. 6. Reinstall the adjustable width arms. Refer to Removing/Installing/Adjusting Arms on page Reinstall the seat assembly onto the scooter. Refer to Removing/Installing the Seat on page 19. NOTE: Mounting positions are in reverse order. For example, Depth-Low is the highest position. Seat Base Mounting Screws Mounting Positions Mounting Screws Depth - Low Back Assembly Seat Base Mounting Screws Depth - Medium Back Assembly Seat Base Mounting Holes Back Assembly Depth - High Mounting Screws Back Assembly Seat Base FIGURE 4.5 Adjusting Seat Depth Zoom 300 and Zoom Part No

23 SECTION 4 SEAT 90 Seat Swivel Adjustment WARNING Ensure that seat is locked into the forward position before and during operation of the scooter. Otherwise, injury to the user and/or damage to the scooter may result. CAUTION DO NOT use the seat swivel option when accessories are installed (such as safety flag, crutch/cane holder, etc.) and the seat is mounted in lowest height adjustment position. Otherwise, damage to the scooter may occur. NOTE: For this procedure, refer to FIGURE 4.6. NOTE: The seat lever is located just beneath the seat on the right side. 8. Pull the seat lever up to rotate the seat. NOTE: The seat locks in position at 90 intervals. The seat is locked when an audible click is heard. 9. Rotate the seat to the desired position. 10. Release seat lever to lock seat in desired position. View From Back Top View Seat Seat Seat Lever FIGURE Seat Swivel Adjustment Part No Zoom 300 and Zoom 400

24 SECTION 4 SEAT Removing/Installing the Seat Positioning Strap WARNING The seat positioning strap is a positioning belt only. It is not designed for use as a safety device withstanding high stress loads such as auto or aircraft safety belts. If signs of wear appear, belt must be replaced immediately. ALWAYS wear your seat positioning strap. NOTE: For this procedure, refer to FIGURE Remove the two (2) mounting screws and washers that secure the seat positioning straps to the arm frame. 2. Remove the halves of the seat positioning strap from the arm frame. 3. Reposition the halves of new seat positioning strap underneath arm frame. 4. Reinstall the two (2) mounting screws and washers that secure the seat positioning straps to the arm frame. Securely tighten. Arm Frame One Half (½) of Seat Positioning Strap Washer One Half (½) of Seat Positioning Strap Mounting Screw Washer Mounting Screw FIGURE 4.7 Removing/Installing the Seat Positioning Strap Zoom 300 and Zoom Part No

25 SECTION 5 ARMS SECTION 5 ARMS WARNING After ANY adjustments, repair or service and BEFORE use, make sure all attaching hardware is tightened securely - otherwise injury or damage may result. Before performing any maintenance, adjustment or service, turn power off and remove key from ignition. Removing/Installing/Adjusting Arms Removing/Installing NOTE: For this procedure, refer to FIGURE 5.1. NOTE: Reverse this procedure to install the arms. 1. Loosen adjustment knob that secures the arm to the arm support bracket. 2. Remove the arm from the arm support bracket. 3. If necessary, repeat STEPS 1-2 to remove the remaining arm. Arm Arm Mounting Tube Adjustment Knobs Arm Support Bracket FIGURE 5.1 Removing/Installing/Adjusting Arms Part No Zoom 300 and Zoom 400

26 SECTION 5 ARMS Adjusting Arm Width NOTE: For this procedure, refer to FIGURE 5.1. NOTE: The arm width can be adjusted between 18 inches and 22 inches. NOTE: Changing the width of the arms may also affect the overall width of the powered scooter. Use caution when traveling through doorways. 1. Loosen the adjustment knob on one (1) arm located beneath the seat frame on the arm support bracket. Refer to FIGURE 5.1. CAUTION The arm can be adjusted to a maximum distance of 4½ inches from the inside of the arm to the top of the mounting shaft. If the arm is adjusted beyond the maximum 4½ inches, the arm will fall out. 2. Move arm in or out to the desired position. 3. Retighten adjustment knob securely. 4. Measure distance between back and inside of arm. NOTE: For proper balance, adjust both arms to the same distance away from the back. 5. Repeat STEPS 1-4 for opposite arm, setting it at the distance determined in STEP 4. Adjusting Arm Angle NOTE: For this procedure, refer to FIGURE 5.2. NOTE: Arm angle can be adjusted between 8 and Lift up the arm. 2. Loosen the jam nut. 3. Adjust the adjustment screw up or down to the desired arm angle. 4. Tighten the jam nut. 5. To position the opposite arm at the same angle, count the exposed threads after the jam nut has been tightened. 6. Set the opposite arm to position determined in STEP 5. Zoom 300 and Zoom Part No

27 SECTION 5 ARMS Arm Adjustment Screw Count Exposed Threads STEP 5 Arm Mounting Tube Jam Nut Adjusting Arm Height FIGURE 5.2 Adjusting Arm Angle NOTE: For this procedure, refer to FIGURE 5.3. NOTE: The arm height can be adjusted between 1 inch and 3 inches. 1. Remove the lock knob that secures the arm to the arm mounting tube. 2. Adjust the arm to desired height. 3. Reinstall the lock knob that secures the arm to the arm mounting tube and tighten securely. 4. Repeat STEPS 1-3 for opposite arm, if necessary. Lock Knob Arm Arm Mounting Tube FIGURE 5.3 Adjusting Arm Height Part No Zoom 300 and Zoom 400

28 SECTION 5 ARMS Replacing Armrest Pads NOTE: For this procedure, refer to FIGURE Remove the two (2) mounting screws that secure the armrest pad to arm. 2. Remove the old armrest pad. 3. Install new armrest pad and securely tighten with existing mounting screws. 4. If necessary, repeat STEPS 1-3 to replace the other armrest pad. Arm Pad Arm Mounting Screws FIGURE 5.4 Replacing Armrest Pads Removing/Installing Arm Support Bracket NOTE: For this procedure, refer to FIGURE 5.5. NOTE: Reverse this procedure to install the arm support bracket. 1. Remove the seat from the scooter. Refer to Removing/Installing the Seat on page Remove the arms from the seat assembly. Refer to Removing/Installing/Adjusting Arms on page Turn the seat over and remove the six (6) mounting screws, washers and spacers that secure the arm support bracket to the seat assembly. 4. Remove the arm support bracket. Zoom 300 and Zoom Part No

29 SECTION 5 ARMS Seat Assembly Side View Arm Spacers Arm Arm Support Bracket Washers Mounting Screws Arm Bottom View Arm Mounting Screws, Spacers, and Washers Arm Support Bracket Mounting Screws, Spacers, and Washers FIGURE 5.5 Removing/Installing Arm Support Bracket Part No Zoom 300 and Zoom 400

30 SECTION 6 SHROUDS SECTION 6 SHROUDS WARNING After ANY adjustments, repair or service and BEFORE use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may result. Before performing any maintenance, adjustment or service, turn power OFF and remove key from ignition. Removing/Installing the Rear Shroud NOTE: For this procedure, refer to FIGURE 6.1. Removing 1. Remove the seat. Refer to Removing/Installing the Seat on page Disengage the hook-and-loop strips securing the rear shroud to the frame by pulling up on the shroud. 3. Lift the rear shroud off the seat post. Installing 1. Align the tabs on the rear shroud with the slots in the front shroud. 2. Place rear shroud on the frame and press down slightly to engage the hook-and-loop strips on the rear shroud (not shown) with those on the scooter frame. 3. Install the seat. Refer to Removing/Installing the Seat on page 19. DETAIL A - ZOOM 300 Rear Shroud DETAIL B - ZOOM 400 Rear Shroud Tabs Hook-and-Loop Strips Frame Tabs Seat Post Seat Post Hook-and-Loop Strips Location of Slots Front Shroud Frame Front Shroud FIGURE 6.1 Removing/Installing the Rear Shroud Hook-and-Loop Strips Zoom 300 and Zoom Part No

31 SECTION 6 SHROUDS Removing/Installing the Front Shroud Zoom 300 NOTE: For this procedure, refer to FIGURE 6.2. NOTE: Reverse this procedure to install the front shroud on the scooter frame. 1. Remove the seat. Refer to Removing/Installing the Seat on page Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page Remove the batteries. Refer to Removing/Installing the Batteries on Zoom 300 on page Disconnect the tiller wiring harness from the rear wiring harness. Refer to FIGURE 8.13 on page page Disengage the boot from the front shroud. Refer to Removing/Installing the Boot Assembly on page Slide the boot up the tiller. 7. Remove the tiller. Refer to Removing/Installing the Tiller on page Remove the floormat on the front shroud by pulling up and away. 9. Remove the four (4) mounting screws that secure the front shroud to the scooter frame. 10. Once the tiller is removed, slide the boot off the tiller and front shroud off the scooter. Mounting Screws Boot Assembly Front Shroud NOTE: Floormat, Tiller and Fork Assemblies, and Scooter frame are not shown. FIGURE 6.2 Removing/Installing the Front Shroud - Zoom 300 Part No Zoom 300 and Zoom 400

32 SECTION 6 SHROUDS Zoom 400 NOTE: For this procedure, refer to FIGURE 6.3. NOTE: Reverse this procedure to install the front shroud on the scooter frame. 1. Remove the seat. Refer to Removing/Installing the Seat on page Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page Remove the batteries. Refer to Removing/Installing the Batteries on Zoom 400 on page Disconnect the tiller wiring harness from the rear wiring harness. Refer to FIGURE 8.14 on page Disengage the boot from the front shroud. Refer to Removing/Installing the Boot Assembly on page Remove the tiller. Refer to Removing/Installing the Tiller on page Remove the floormat on the front shroud by pulling up and away. 8. Remove the four (4) mounting screws that secure the front shroud to the scooter frame. 9. Once the tiller is removed, slide the boot off the tiller and front shroud off the scooter. NOTE: The boot will have to be slipped off the front basket bracket after disengaging the boot from the tabs. 10. Mounting Screws Boot Assembly Front Shroud Front Basket Bracket goes through HERE NOTE: Floormat, tiller and fork assemblies, and scooter frame are not shown. FIGURE 6.3 Removing/Installing the Front Shroud - Zoom 400 Zoom 300 and Zoom Part No

33 Removing/Installing the Boot Assembly SECTION 6 SHROUDS NOTE: For this procedure, refer to FIGURE 6.4. NOTE: Reverse this procedure to install the boot assembly. 1. Remove the front shroud. Refer to Removing/Installing the Front Shroud on page Remove the tiller. Refer to Removing/Installing the Tiller on page Remove the front shroud and boot assembly from the scooter. 4. Remove the boot assembly from the front shroud by disengaging the boot from the tabs on the front shroud. NOTE: On the Zoom 400, the boot will have to be slipped off the front basket bracket after disengaging the boot from the tabs. Refer to Detail A of FIGURE 6.4. Tab Boot Assembly DETAIL A Boot Assembly Front Basket Bracket Front Basket Bracket Front Shroud Front Shroud NOTE: The Zoom 400 is shown. The Zoom 300 is the same without the front basket bracket. FIGURE 6.4 Removing/Installing the Boot Assembly Part No Zoom 300 and Zoom 400

34 SECTION 7 WHEELS AND CASTERS SECTION 7 WHEELS AND CASTERS WARNING After any adjustments, repair or service and before use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may result. Before performing any maintenance, adjustment or service, turn power Off and remove key from ignition. Removing/Installing the Drive Wheels NOTE: For this procedure, refer to FIGURE 7.1. Removing 1. Turn power off and remove the key from the ignition. 2. Remove the seat. Refer to Removing/Installing the Seat on page Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page Place the scooter frame up on blocks so that the drive wheels are off the ground. 5. Remove the hex nut and washer that secure the drive wheel to the drive shaft. Discard hex nut. 6. Use a wheel puller, if necessary, to remove the existing drive wheel from the drive shaft. 7. Remove keystock from drive shaft. Set aside. 8. If necessary, repeat STEPS 1-6 to remove other drive wheel. Installing 1. Place keystock in cutout on drive shaft as shown in FIGURE 7.1. NOTE: The keystock in the drive shaft MUST lineup with the cutout in the wheel hub. 2. Install the drive wheel onto the drive shaft. NOTE: If necessary, use a rubber hammer to gently tap drive wheel completely into position on the drive shaft. 3. Secure wheel to drive shaft using the washer and new hex nut. Securely tighten. NOTE: A new hex nut should be used when reinstalling the wheel. 4. Repeat STEPS 1-3 to install the other drive wheel. 5. Install the rear shroud. Refer to Removing/Installing the Rear Shroud on page Install the seat. Refer to Removing/Installing the Seat on page 19. Zoom 300 and Zoom Part No

35 SECTION 7 WHEELS AND CASTERS DETAIL A - ZOOM 300 Keystock Warning: Pinch Point Drive Shaft Cutout Hex Nut Washer Scooter Frame Drive Wheel DETAIL B - ZOOM 400 Swingarm Scooter Frame Keystock Transaxle Assembly Hex Nut Washer Drive Shaft Drive Wheel Cutout FIGURE 7.1 Removing/Installing the Drive Wheels Part No Zoom 300 and Zoom 400

36 SECTION 7 WHEELS AND CASTERS Removing/Installing the Front Wheel NOTE: For this procedure, refer to FIGURE 7.2. NOTE: Take note of position and orientation of wheel and mounting hardware before removing. Removing 1. Turn power off and remove the key from the ignition. 2. Place the front of the powered scooter up on blocks so that the front wheel is off the ground. 3. Remove the mounting screw, locknut and two (2) spacers that secure the front wheel to the fork. 4. Remove front wheel from fork. Installing WARNING Front wheel MUST be mounted in the lower mounting holes for both the Zoom 300 and Zoom otherwise injury may result. NOTE: Before installing the front wheel, check the fork for bending. If bent, replace the fork. Refer to Removing/Installing the Fork on page Align front wheel with the lower fork mounting holes. 2. Secure the front wheel to the fork using the mounting screw, locknut and two (2) spacers. 3. Securely tighten the front wheel mounting hardware. Fork Lower Fork Mounting Hole Spacer Locknut Mounting Screw Spacer Front Wheel FIGURE 7.2 Removing/Installing the Front Wheel Zoom 300 and Zoom Part No

37 Removing/Installing the Fork SECTION 7 WHEELS AND CASTERS NOTE: For this procedure, refer to FIGURE 7.3, FIGURE 12.2, and FIGURE Removing 1. Remove the seat. Refer to Removing/Installing the Seat on page Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page Disconnect the RED and BLACK battery connector from the wiring harness assembly. Refer to FIGURE 12.2 on page 87 for the Zoom 300 and FIGURE 12.3 on page 89 for the Zoom Remove the boot assembly. Refer to Removing/Installing the Boot Assembly on page Remove the tiller. Refer to Removing/Installing the Tiller on page Remove the two (2) mounting bolts that secure the tiller angle adjustment assembly to the front fork. Refer to FIGURE Slide front fork out of the fork stem mount on the scooter frame. Installing 1. Slide front fork into the fork stem mount. 2. Place the tiller angle adjustment assembly on the front fork. 3. Install the two (2) mounting bolts to secure tiller angle adjustment assembly to the front fork. Securely tighten (FIGURE 7.3). 4. Install the tiller assembly. Refer to Removing/Installing the Tiller on page Install the boot assembly. Refer to Removing/Installing the Boot Assembly on page Connect the RED and BLACK battery connector to the wiring harness assembly. Refer to FIGURE 12.2 on page 87 for the Zoom 300 and FIGURE 12.3 on page 89 for the Zoom Install the rear shroud. Refer to Removing/Installing the Rear Shroud on page Install the seat. Refer to Removing/Installing the Seat on page 19. Part No Zoom 300 and Zoom 400

38 SECTION 7 WHEELS AND CASTERS Tiller Angle Adjustment Assembly Washers Mounting Screws Scooter Frame NOTE: Zoom 300 frame is shown. Front fork mounts the same way to Zoom 400. Front Fork Fork Stem Mount FIGURE 7.3 Removing/Installing the Fork Removing/Installing the Caster Assemblies NOTE: For this procedure, refer to FIGURE 7.4. Removing 1. Use a wrench to turn the hex nut on the caster assembly counter-clockwise to loosen and remove the caster wheel. 2. If necessary, repeat STEPS 1 to remove the other caster. Installing 1. Insert the caster wheel into the caster housing and turn the hex nut clockwise to securely tighten the caster wheel in place. Caster Housing Hex Nut Swingarm Assembly Caster FIGURE 7.4 Removing/Installing the Caster Assemblies Zoom 300 and Zoom Part No

39 SECTION 7 WHEELS AND CASTERS Replacing Foam-Filled Tires Onto Wheel Rims NOTE: For this procedure, refer to FIGURE 7.5. NOTE: During initial use of scooter, user may experience a flat spot on wheels. Flat spot will disappear with continual use of scooter. 1. Remove the wheel from the drive shaft. Refer to Removing/Installing the Drive Wheels on page Perform one (1) of the following: Replacing Existing Tire and Rim: Discard existing tire and hub. Proceed to STEP 3. Replacing Existing Rim Only: Perform the following - i. Remove the four (4) existing mounting screws, lock washers and nuts that secure the existing outer rim, inner rim and hub to the existing tire. ii. Discard existing mounting hardware, rims and hub. 3. When installing the new two-piece hub into a new pneumatic tire, if necessary, place the inner tube into the tire. 4. Insert the outer rim and inner rim into the new/existing tire. 5. Insert the hub into the inner rim and align the four (4) mounting holes of the hub, inner rim and outer rim. 6. Using the four (4) mounting screws, lock washers and hex nuts, secure the outer rim to the inner rim and hub. Torque hex nuts to in-lbs ± Install the drive wheel on the drive shaft. Refer to Removing/Installing the Drive Wheels on page 34. Washers Outer Rim Locknuts Mounting Screws Hub Wheel Hub Cutout Inner Rim FIGURE 7.5 Replacing Foam-Filled Tires Onto Wheel Rims Part No Zoom 300 and Zoom 400

40 SECTION 8 TILLER SECTION 8 TILLER WARNING After any adjustments, repair or service and before use, make sure that all attaching hardware is tightened securely - otherwise injury or damage may result. Before performing any maintenance, adjustment or service, turn power OFF and remove key from ignition. Removing/Installing the Tiller Zoom 300 NOTE: For this procedure, refer to FIGURE 8.1, FIGURE 8.13, and FIGURE NOTE: Reverse this procedure to install the tiller. 1. Turn power off and remove the key from the ignition. 2. Remove the seat. Refer to Removing/Installing the Seat on page Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page Disconnect the controller from the batteries by pulling the RED and BLACK controller connector from the RED and BLACK battery connector. Refer to FIGURE 12.2 on page Remove the basket. Refer to Removing/Installing the Front Basket on page Disengage the boot and slide it up the tiller to expose the tiller angle adjustment assembly. 7. Disconnect the tiller wiring harness from the rear wiring harness. Refer to FIGURE 8.13 on page Remove the upper tiller shroud. Refer to Removing/Installing the Upper Tiller Shroud on page Remove the mounting screw and P clip securing the tiller harness cable to the tiller (Detail C of FIGURE 8.1.). 10. Pull the tiller harness cable through the hole in the lower tiller shroud. 11. Remove the two (2) locknuts, mounting screws, tube clamps and cable bracket that secure the tiller to the tiller angle adjustment assembly (Detail A of FIGURE 8.1). 12. Disconnect the tiller angle adjustment cable from the actuator wedge by performing the following (Detail D of FIGURE 8.1.): A. Lift up the actuator wedge until the tiller angle adjustment cable is slack. B. Pull the tiller angle adjustment cable from the actuator wedge. 13. Remove the tiller. Zoom 300 and Zoom Part No

41 Zoom 400 SECTION 8 TILLER NOTE: For this procedure, refer to FIGURE 8.1, FIGURE 8.14 and FIGURE NOTE: Reverse this procedure to install the tiller. 1. Turn power off and remove the key from the ignition. 2. Remove the seat. Refer to Removing/Installing the Seat on page Remove the rear shroud. Refer to Removing/Installing the Rear Shroud on page Disconnect the two (2) BLACK battery connectors from the wiring harness connectors. Refer to FIGURE 12.3 on page Remove the rear tiller shroud. Refer to Removing/Installing the Rear Tiller Shroud on page Remove the headlight. Refer to Removing/Installing the Headlight on page Remove the headlight mounting bracket and front tiller shroud. Refer to Removing/ Installing the Headlight Mounting Bracket/Front Tiller Shroud on page Disengage the boot and slide it up the tiller to expose the tiller angle adjustment assembly. NOTE: The boot will have to be slipped off the front basket bracket after disengaging the boot from the tabs. 9. Disconnect the tiller wiring harness from the rear wiring harness. Refer to FIGURE 8.14 on page Cut the tie-wrap securing the tiller harness cable and tiller angle adjustment cable to the tiller. 11. Remove the upper tiller shroud. Refer to Removing/Installing the Upper Tiller Shroud on page Remove the mounting screw and P clip securing the tiller harness cable to the tiller (Detail C, FIGURE 8.1.) 13. Pull the tiller harness cable through the hole in the lower tiller shroud. 14. Remove the two (2) locknuts, mounting screws, tube clamps and cable bracket that secure the tiller to the tiller angle adjustment assembly (Detail B of FIGURE 8.1). 15. Disconnect the tiller angle adjustment cable from the actuator wedge by performing the following (Detail D of FIGURE 8.1.): A. Lift up the actuator wedge until the tiller angle adjustment cable is slack. B. Pull the tiller angle adjustment cable weight from the actuator wedge. 16. Remove the tiller. Part No Zoom 300 and Zoom 400